Chicago Electric 96617 Set Up And Operating Instructions Manual Download

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6300 watt gasoline

generator

Model

96617

set up and operating instructions

Diagrams within this manual may not be drawn proportionally.

Due to continuing improvements, actual product may differ slightly from the product described herein.

distributed exclusively by Harbor Freight tools

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our website at: http://www.harborfreight.com

read this material before using this product.

Failure to do so can result in serious injury.

saVe tHis Manual.

2007 by Harbor Freight Tools

manual or any artwork contained herein may be reproduced in any shape or form

without the express written consent of Harbor Freight Tools.

For technical questions or replacement parts, please call 1-800-444-3353.

Summary of Contents for 96617

Page 1: ...3491 Mission Oaks Blvd Camarillo CA 93011 Visit our website at http www harborfreight com Read this material before using this product Failure to do so can result in serious injury Save this manual Copyright 2007 by Harbor Freight Tools All rights reserved No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor ...

Page 2: ...ols Tools with Two Prong Plugs 10 Extension Cords 10 Symbology 11 Unpacking 12 Set Up Instructions 12 Assembly 13 To Install The Battery 13 Operating Instructions 13 INSTALLATION INSTRUCTIONS 14 Grounding The Generator 14 Control Panel Features 15 PRE START INSTRUCTIONS 16 To Add Engine Oil 16 To Fill The Fuel Tank 17 OPERATING INSTRUCTIONS 17 To Connect Electrical Loads 18 INSPECTION MAINTENANCE ...

Page 3: ...shaft Assembly 29 Parts List Diagram G Recoil Starter Assembly 30 Parts List Diagram H Fan Cover Assembly 31 Parts List Diagram J Carburetor System 31 Parts List Diagram K Flywheel System 32 Parts List Diagram L Ignition System 32 Parts List Diagram M Starter Motor System 33 Parts List Diagram N Control System 33 Parts List Diagram P Muffler System 34 Parts List Diagram R Air Cleaner 35 Parts List...

Page 4: ... the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION used with the safety al...

Page 5: ...hile operating a Gasoline Generator Distractions can cause you to lose control Provide barriers or shields as needed Electrical Safety All connections and conduits from the Generator to the load must only be installed by trained and licensed electricians and in compliance with all relevant local state and federal electrical codes and standards and other regulations The Generator must be grounded i...

Page 6: ...parts Loose clothes jewelry or long hair can be caught in moving parts Remove adjusting keys or wrenches before turning the Generator on A wrench or a key that is left attached to a rotating part of the machine may result in personal injury Do not reach over or across the Generator Keep proper footing and balance at all times Use safety equipment Always wear eye protection Safety equipment such as...

Page 7: ...ious injury could result if the Generator tips Never leave the Generator unattended when it is running Turn off the Engine before leaving This Generator is designed for outdoor use only Do not operate the Generator in a closed area or in a poorly ventilated area When running the Engine of this Generator produces carbon monoxide a colorless odorless toxic fume that when inhaled can cause serious pe...

Page 8: ...gnition around the Generator Keep grounded conductive objects such as tools away from exposed live electrical parts and connections to avoid sparking or arcing These events could ignite fumes or vapors Do not refill the Fuel Tank while the Engine is running or while the Engine is still hot Do not operate the Generator with known leaks in the fuel system Use only recommended fuel and oil MECHANICAL...

Page 9: ...alled by a qualified electrician Grounded Tools Tools with Three Prong Plugs Tools marked with Grounding Required have a three wire cord and three prong grounding plug The plug must be connected to a properly grounded outlet If the tool should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from the user reducing the risk of electric shock ...

Page 10: ...n cord Double Insulated tools can use either a two or three wire extension cord As the distance from the supply outlet increases you must use a heavier gauge extension cord Using extension cords with inadequately sized wire causes a serious drop in voltage resulting in loss of power and possible tool damage See Table A The smaller the gauge number of the wire the greater the capacity of the cord F...

Page 11: ...UM WIRE GAUGE FOR EXTENSION CORDS 120 240 VOLT NAMEPLATE AMPERES at full load EXTENSION CORD LENGTH 25 Feet 50 Feet 75 Feet 100 Feet 150 Feet 0 2 0 18 18 18 18 16 2 1 3 4 18 18 18 16 14 3 5 5 0 18 18 16 14 12 5 1 7 0 18 16 14 12 12 7 1 12 0 18 14 12 10 12 1 16 0 14 12 10 16 1 20 0 12 10 TABLE A Based on limiting the line voltage drop to five volts at 150 of the rated amperes Symbology Double Insul...

Page 12: ...erall Dimensions 28 3 8 L x 20 1 8 W x 21 7 8 H Run Time 9 hour continuous run time at 50 load Weight 196 Pounds The Emission Control System for this engine is warranted for standards set by the U S Environmental Protection Agency and by the California Air Resources Board also known as CARB For warranty information refer to the last pages of this manual Unpacking When unpacking check to make sure ...

Page 13: ...ections Remove the packing from the battery Then locate the factory pre installed battery guard plate and battery tray beneath the control panel of the generator unit See Figure B Slide the battery into the battery guard plate with the battery s terminals facing outward and with the battery s negative terminal facing left Align the two mounting holes in the battery bracket with the two threaded mo...

Page 14: ...ailable Locate the Generator so that the air inlets and outlets are not blocked by obstructions such as bushes trees or snow drifts Locating it in the path of heavy winds or snowdrifts may require the placement of a barrier for protection The air inlet on Air Cleaner Cover 2R in normal weather conditions should face the prevailing wind direction Locate the Generator on a concrete slab or other are...

Page 15: ... Fuel Tank Cap removed 120 Volt AC Outlets 49 The Generator is equipped with four 3 hole 120 volt AC outlets to power 120 volt tools and equipment There is a circuit breaker that protects the Generator from overloading Should a Circuit Breaker trip unplug all electrical loads from the Generator Allow the Circuit Breaker to cool down Then push the Circuit Breaker back up 240 Volt AC Outlet 48 The G...

Page 16: ...th low or no engine oil Running the engine with low or no oil will permanently damage the Engine Oil Dipstick Fuel Tank 1S Fuel Gauge Fuel Filter 9S Fuel Filler Cap 11S FIGURE E The Engine MUST be filled with a high quality grade engine oil If the Engine will be run in temperatures above 32 degrees Fahrenheit use SAE 30 weight oil If the Engine will be run in temperatures below 32 degrees Fahrenhe...

Page 17: ...e s crankcase prior to starting and running the Engine Failure to add oil will damage the Engine and void the warranty Before the first use the Fuel Tank 1S must be filled with a high octane unleaded gasoline Never fill the Fuel Tank completely Fill the Fuel Tank to 1 2 below the bottom of the filler neck to provide space for fuel expansion Wipe any fuel spills from the Engine and Generator before...

Page 18: ...nect 240 AC appliances tools and equipment only to the 240V AC Outlet Connect 12V DC appliances tools and equipment only to the 12V DC Terminal See Figure D Never exceed the rated capacity for this Generator as serious damage to the Generator and or appliances tools and equipment could result from an overload Starting and running wattage requirements should always be calculated when matching this ...

Page 19: ...ator disconnect all electrical loads Turn the Ignition Switch 38 to the OFF position to stop the Engine Then close the Engine Fuel Valve INSPECTION MAINTENANCE AND CLEANING WARNING Always make sure the Engine Ignition is in the OFF position the Key is removed from the Ignition and the Spark Plug wire is disconnected prior to performing any service maintenance or cleaning of the Generator or Engine...

Page 20: ... sure to dispose of the old oil according to local waste disposal requirements After every 25 hours of use Service the Air Cleaner Element 4R and Air Outer Filter 5R To do so remove the Air Cleaner Cover 2R Remove the Air Filter Element Immerse the Air Filter Element in a mild solvent and rinse the Element several times to clean Remove the Element from the solvent and squeeze thoroughly to dry The...

Page 21: ... of any kind to the buyer that he or she is qualified to make any repairs to the product or that he or she is qualified to replace any parts of the product In fact the manufacturer and or distributor expressly states that all repairs and parts replacements should be undertaken by certified and licensed technicians and not by the buyer The buyer assumes all risk and liability arising out of his or ...

Page 22: ...Page 22 SKU 96617 For technical questions please call 1 800 444 3353 troubleshooting ...

Page 23: ...racket 1 25 Nut M8 12 26 Engine 1 Part Description Qty 27 45 Vibration Mount 4 28 Flat Washer 8 29 Spring Washer 8 30 Nut M10x1 25 8 31 Nut M6 4 32 Screw M6x16 4 33 Control Wire Harness Boot 1 34 Back Housing 1 35 AC Output Wire Boot 1 36 Front Panel 1 37 Screw ST4 2x12 8 38 Ignition Switch 1 39 Key 2 40 Oil Indicator 1 41 DC Terminal 2 42 Circuit Breaker 12A 50VDC 1 43 Volt Indicator 1 44 Voltmet...

Page 24: ...Page 24 SKU 96617 For technical questions please call 1 800 444 3353 Main Unit Assembly Diagram ...

Page 25: ... 6A Flange Bolt M10x80 4 7A Spark Plug 1 8A Exhaust Pipe Stud Bolt 2 9A Cylinder Head 1 10A Carburetor Stud Bolt 2 11A Cylinder Head Sealing Pad 2 12A Dowel Pin 10x12x20 2 13A Breather Tube 1 Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts Note When ordering parts from this list the suffix A must be used at the end of the...

Page 26: ... 1 7B Washer 8 3x17x1 1 8B Lock Pin 10mm 1 9B Governor Arm Shaft 1 10B Oil Seal 8x14x5 1 11B Drain Plug Washer 12mm 2 12B Drain Plug Bolt 2 13B Oil Seal 35x52x8 1 14B Oil Protector 1 15B Ball Bearing 1 Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts Note When ordering parts from this list the suffix B must be used at the ...

Page 27: ...g 1 7C Ball Bearing 1 Part Description Qty 8C Slider Shaft 1 9C Governor Gear Washer 6mm 1 10C Governor Gear 1 11C Slider Washer 6mm 1 12C Governor Slider 1 13C Crankcase Cover Pad 1 14C Dowel Pin 8x12 2 Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts Note When ordering parts from this list the suffix C must be used at th...

Page 28: ...mpression Ring B 1 3E Oil Ring A 2 4E Oil Ring B 1 5E Pistion Pin Clip 20mm 2 6E Piston 1 Part Description Qty 7E Piston Pin 1 8E Connecting Rod 1 9E Connecting Rod Cap 1 10E Connecting Rod Bolt 2 11E Piston Ring Set 1 Note Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts Note When ordering parts from these lists the suffix D or...

Page 29: ...shaft and Gear Assy 1 9F Exhaust Valve Cap 1 10F Exhaust Valve Spring Retainer 1 11F Valve Spring 2 12F Valve Spring Seat 2 13F Intake Valve Spring Retainer 1 14F Exhaust Valve 1 15F Intake Valve 1 16F Rocker Assembly 1 Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts Note When ordering parts from this list the suffix F mu...

Page 30: ...5G Starter Ratchet 2 6G Ratchet Spring 2 7G Recoil Starter Reel 1 8G Start Return Spring 1 9G Recoil Starter Case 1 10G Recoil Starter Rope 1 11G Starter Grip 1 12G Flange Bolt M6x8 Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts Note When ordering parts from this list the suffix G must be used at the end of the number to...

Page 31: ...rts List Diagram J Carburetor System Part Description Qty 1J Intake Pipe Gasket 1 2J Carburetor Insulating Plate 1 3J Carburetor Paper Gasket 1 4J Carburetor Assembly 1 5J Carburetor Iron Gasket 1 Note Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts Note When ordering parts from these lists the suffix H or J must be used at the...

Page 32: ...scription Qty 1L Plenum Cap 1 2L Ignition Coil Assembly 1 3L Stop Switch Cord 1 4L Stop Switch Cord Holder 1 5L Flange Bolt M6x25 2 6L Cord Grommet 1 7L Charge Coil Assembly 1 8L Flange Bolt M6x40 2 9L Cord Clamp 1 10L Flange Bolt M6x20 1 Note Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts Note When ordering parts from these l...

Page 33: ...ontrol Base 1 3N Control Adjusting Spring 1 4N Screw M5x34 1 5N Flange Bolt M6x14 1 6N Governor Spring 1 Part Description Qty 7N Throttle Return Spring 1 8N Governor Rod 1 9N Flange Nut M6 1 10N Governor Arm Bolt M6 1 11N Control Arm 1 Note Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts Note When ordering parts from these list...

Page 34: ...Muffler 1 4P Spark Arrester 1 5P Exhaust Pipe Gasket 1 6P Exhaust Pipe 1 7P Muffler Gasket 1 8P Flange Nut M8 2 9P Muffler Assembly 1 Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts Note When ordering parts from this list the suffix P must be used at the end of the number to identify the correct part ...

Page 35: ... Silencer Nose 1 7R Elbow Packing 1 Part Description Qty 8R Flange Bolt M6x20 1 9R Air Cleaner Collar 1 10R Air Cleaner Elbow 1 11R Air Cleaner Collar 1 12R Flange Nut M8 2 13R Air Cleaner Assembly 1 Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts Note When ordering parts from this list the suffix R must be used at the en...

Page 36: ... Description Qty 7S Fuel Tank Joint 1 8S Flange Nut M6 1 9S Fuel Filter 1 10S Fuel Filter Cap Packing 1 11S Fuel Filler Cap Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts Note When ordering parts from this list the suffix S must be used at the end of the number to identify the correct part Parts List Diagram T Control Bo...

Page 37: ...s Board herein CARB the United States Environmental ProtectionAgency herein EPA and Harbor Freight Tools herein HFT are pleased to explain the emission control system warranty on your 1995 and later Small Off Road Engine herein engine In California the engine must be designed built and equipped to meet the State s stringent anti smog standards Elsewhere within the United States new off road spark ...

Page 38: ...rized by HFT b improper installation adjustment or repair of the engine or of any warranted part unless performed by an authorized warranty center c failure to follow recommendations on fuel use contained in the Owner s Manual d improper or inadequate maintenance of any warranted parts e repairs performed outside of the authorized warranty service dealers f alterations by changing adding to or rem...

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